Electric switch toggle assembly

ABSTRACT

Toggle element structure for electric switch which enables assembly of unitary toggle element with large head by extending narrow shaft thereof through cover plate from external side thereof with a pivot ball staked on said shaft from the interior side of said cover plate.

United States Patent 11 1 Discenza 1451 Feb. 18, 1975 ELECTRIC SWITCH TOGGLE ASSEMBLY 3,818,154 6/1974 Presently 1. 200/6 A [75] Inventor: Frank J. Discenza, Rocky Hill, FOREIGN PATENTS OR APPLICATIONS Conn" 1,961,543 6/1970 Germany 200/6 A [73] Assignee: Carling Electric, Inc., West Hartford, Primary Examiner-James R. Scott Assistant ExaminerWilliam J. Smith 22 l- 7 I Dec l9 3 Attorney, Agent, or Firml. Jordan Kumk [21] Appl. No.: 425,727

[57] ABSTRACT 52 l. E 5 200/329 Toggle element structure for electnc swltch wh1ch en- [58] Field A 153 ables assembly of unitary toggle element with large 29/622 head by extending narrow shaft thereof through cover plate from external side thereof with a pivot ball [56] References Cited staked on said shaft from the interior side of said 1 t UNITED STATES PATENTS cover p a 6 2,984,720 5/1961 Fischer 200/6 A 6 Claims, 10 Drawing Figures SHEET 2 OF 2 Pmgmgmmx 8W5 FIG. 9

FIG. IO

ELECTRIC SWITCH TOGGLE ASSEMBLY BACKGROUND OF THE INVENTION I cover plate-bushing assembly after which the ball collar is staked upon the shaft to provide a pivot bearing for the reciprocating action of said toggle element.

2. Description of the Prior Art Past efforts to provide nylon actuator toggle switches have often resulted in the .toggle being too weak and subject to breaking or bending under pressure. This breaking especially occurred when the whole toggle was made of plastic. In order to alleviate the problem of breakage, others have designed an external plastic actuator cap which is pushed onto a metal toggle extending through a bushing into theswitch case. The portion of the metal toggle extending externally above the bushing is designed with barbs to securely bite into and hold the nylon cap. Thus, the toggle actuator has the necessary strength as provided by the metal extension onto which the nylon cap is firmly staked. However, this method of construction is very costly due to the configuration of the metal actuator toggle. This part is manufactured on a screw machine and the multiple flat surfaces and angled barbs required to bite into the nylon necessitate secondary operations resulting in a very high cost for what should be a relatively inexpensive part.

SUMMARY OF THE INVENTION The solution in the present invention for the problems of strength and cost are comprised in two simple and inexpensive parts: one metal, one plastic. In order to provide the necessary strength for multiple switching operations, the plastic actuator protruding above the bushing must be relatively thick. Because of the thickness required, the toggle cannot be assembled by moving it through the bushing from the bottom as is done in the assembly ofa'standard toggle switch with a metal toggle and, likewise, in the assembly of switches with all plastic toggles. The switch assembly herein permits assembly of the toggle element through the top of the bushing on the switch case cover plate.

The conventional switch toggle element usually has formed thereon a pivot ball located approximately at the middle and intermediate ends thereof. This ball portion is larger than the opening at the top of the bushing in order to keep the toggle from falling out of the top of the bushing and to provide a bearing surface upon which the toggle will pivot when actuated. Since the plastic toggle herein is assembled through the top of the bushing, the necessary pivot ball must be attached to the toggle after the toggle is inserted into the bushing. Accordingly, there is provided a small metal or plastic ball with a hole through its center which is staked onto the portion of the plastic toggle extending into the switch. When a metal ball is employed, the hole through the ball is slightly smaller than the nylon portion of the toggle onto which it is staked, thus providing for a secure mounting. When a plastic ball is used, ridges may be molded into the toggle element allowing the ball to snap over said ridge and be secured locked in place. The ball is urged pivotally against an accommodating bearing seat formed in the interior of the bushing. This allows the plastic toggle to have the necessary thickness above the pivot point required for the proper toggle strength, yet employs only two inexpensive, easily assembled parts.

This toggle assembly provides for a sufficiently large mass external of the switch while the comparatively slender shaft thereof is provided with a strong and sturdy pivot element in the form of the staked metal or plastic ball, said components being very inexpensive and easily assembled. The structure described and claimed herein results in considerably reduced cost of production and consequent lower cost to the consumer.

These and other novel features and advantages of the present invention will be described and defined in the following specification and claims.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the assembled switch apparatus of the present invention;

FIG. 2 is a greatly enlarged vertical central section view taken on line 22 of FIG. 1, some parts. being shown in elevation and some parts being omitted;

FIG. 3 is a view taken on line 3-3 of FIG. 2, some parts being omitted;

FIG. 4 is a view taken on line 4-4 of FIG. 3, some DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings in detail, there is shown in FIGS. 1 5, an electric switch comprising a rectangular case generally designated 21, having spaced parallel side walls 22 and 23, and spaced parallel end walls 24 and 26. Molded integrally with the bottom portions of said side walls and end walls is a floor 27 together forming an open top rectangular enclosure for the switching elements of the apparatus.

Extending between end walls 24 and 26, and intermediate side walls 22 and 23, is a vertical partition 28 that is formed integrally with said floor and said end walls. Said partition, the top of which has a concave curvature, extends approximately half-way intermediate the top'and bottom of said switch case to divide the latter into separate parallel switch compartments. Case 21 and partition 28 are formed of a suitable insulating material such as nylon, Bakelite, or the like.

Extending through the central portion of floor 27 is a pair of electrically conducting spaced studs 29 and 31. Secured by the upper ends of studs 29 and 31 to the interior surface of floor 27 are electrically conductive yoke bases 32 and 33, respectively. integrally formed on each base 32 and 33 are upwardly extending spaced pairs of arms 36, 37, and 38, 39. integrally formed on arms 36, 37 and 38, 39 are pairs of upwardly extending fingers 41. See also FiG.9. Rocking on each yoke between fingers 41 is an elongated electrically conductive lever arm 42, upon the ends of which are mounted electrically conductive contact elements 43 and 44, respectively. Midway between the ends of lever arm 42 and integrally formed thereon is'a pair of extending tabs 46, each of which extends outwardly between respective pairs of fingers 41 on each side of the respective yoke, and bearing pivotally upon convex projections 47 formed on the top of arms 36, 37 and arms 38, 39 of said yokes. Partition 28 located between the two sets of switching elements serves as an insualting barrier therebetween.

Secured to the bottom of the external surface of floor 27 by means of studs 29 and 31 are electrically conductive terminal elements 48 and 49 having integrally formed, downwardly extending terminal lugs 51 and 52,'respectively, for connection to a common power source, for example.

Extending through floor 27 on one side of partition 28 are spaced circuit studs 53 and 54, the upper ends of which terminate in contact heads 56 and 57, respectively. Secured to the exterior bottom surface of floor 27 by means of circuit studs 53 and 54 are terminal elements 58 and 59, respectively, having integrally formed, downwardly extending terminal lugs 61 and 62, respectively. Each of said lugs is connectibie to a separate electrical circuit operated by said switch, with a respective terminal lug 51 being connected to a comiTlOl'l POWBI' source.

One of the lever arms 42 pivotally moves on one of the yokes to alternatively open and close an electrical circuit between said yoke and a respective contact head 56 or 57.

On the other side of partition 28, electrically conductive spaced studs 63 and 64 extend through floor 27, the upper ends of said studs terminating in contact heads 66 and 67, respectively. The bottom portions of studs 66 and 67 secure to the external bottom surface of floor 27 terminal elements 68 and 69, respectively, each having integrally formed, downwardly extending terminallugs 71 and 72 that are connectible to separate electrical circuits alternatively opened and closed by means of the pivoting action of a second contact lever 42. A common power source is connected to terminal lug 52 to provide electrical energy for the operation of circuits to which terminal lugs 71 and 72 are connected.

The open top of switch case 21 is covered by a sheet metal cover plate 73 having integrally formed, downwardly extendingspaced legs 74, 76 terminating in spaced fingers 77 which are bent inwardly to engage a respective shoulder 78 and 79 in walls 24 and 26 of the switch case. See also FIG. 7.Legs 74, 76 lie flat within suitable recesses in the external surface of end walls 24, 26. Cover plate 73 has a central aperture to which is secured the lower end of an upwardly extending threaded bushing 81. integrally formed in the upper portion of bushing 81 is an inwardly extending annular shoulder 82, the inner portion of which is formed into an arcuate shaped annular bearing seat 83. Extending through the center of bushing 81 is a toggle shaft 84, at the upper end of which is integrally formed a toggle handle 86,

the dimensions of which are greater than that of the inside diameter of shoulder 82 which can only accommodate shaft 84 freely therethrough. The unitary element comprising toggle shaft 84 and toggle handle 86 is made of a suitable material such as nylon or Bakelite.

After toggle shaft 84 is inserted downwardly through the aperture formed by shoulder 82 and is positioned longitudinally through bushing 81, a ball-shaped collar 87 having a central aperture 88 is staked upon toggle shaft 84 until it abuts annular shoulder 89 formed at the upper portion of said toggle shaft. See FIGS. 7 and 8. The diameter of aperture 88 is slightly smaller than the diameter of toggle shaft 84 whereby collar 87 is firmly secured to shaft 84 by a stong friction or snap-on fit.

Collar 87 is made of a suitable strong material such as steel, brass, nylon, or the like.

The arcuate contour of annular bearing seat 83 is matched by the circular external contour of collar 87 whereby a smooth sliding action is provided between said bearing surface and the surface of collar 87 to facilitate the pivoting action of toggle shaft 84 and of toggle handle 86.

integrally formed on the lower end of toggle shaft 84 is a downwardly extending plug 91 having a rectangular or square cross-section which slidabiy cooperates with a comparably shaped socket 92 within switch lever ac tuator 93. Actuator 93 extends laterally on both sides of socket 92 and the bottom thereof has a pair of spaced upwardly extending recesses 94 and 96 which accommodate captive springs 97 and 98, respectively. A pair of lever actuating nibs 101 and 102 are provided for recesses 94 and 96, each nib having a recess 103 and 104 which accommodates the lower portions of springs 97 and 98 for yieidable longitudinal action of said nibs within recesses 94 and 96, respectively. Nibs 101 and 102 each bear upon a respective lever arm 42 whereby the pivoting motion of toggle shaft 84 and of toggle handle 86 cause said nibs to move along the top surface of said respective switch levers to produce the switching action between said levers and respective pairs of contact heads 56, 57 and 66, 67.

The bottom central portion of actuator 93 has a recess 106 to provide clearance between actuator 93 and the top arcuate edge of partition 28 when said actuator moves between the extreme of its alternate switching positions by the action of toggle shaft 84.

While springs 97 and 98 serve to provide yieidable pressure upon nibs 101, 102 when moving along the curved surfaces of levers 42, said springs also serve to provide upward pressure upon collar 87 to urge the latter into positive nesting and sliding relationship to arcuate annular bearing seat 83.

Although the drawings and description disclose a toggle switch operating two separate circuit configurations, it is understood that the principle of the present Although the present invention has been described with reference to particular embodiments and examples, it will be apparent to those skilled in the art that variations and modifications can be substituted therefor without departing from the principles and true spirit of the invention. The Abstract given above is for the convenience of technical searchers and is not to be used for interpreting the scope of the invention or claims.

I claim:

1. An electric switch comprising a case, a bushing mounted on said case, an annular curved shoulder in the interior of said bushing, a toggle element extending through said bushing and the aperture formed by said shoulder and into the interior of said case for pivotally actuating the switch, said toggle element being made of a stiff material, a portion of said toggle element extending externally of said bushing and being larger than said aperture, a stem portion on said toggle element of smaller cross-section than said aperture and extending therethrough, a pivot ball, an aperture in said pivot ball, said ball aperture being slightly smaller in diameter than the diameter of said stem, said pivot ball being staked upon said stem to a position where its surface pivotally bears against the matching curved surface of said shoulder.

2. A switch according to claim 1 and further comprising at least one pivoting switching element in the interior of said case, an actuator mounted on the inner end of said stem and operative upon said switching element, a spring element on said actuator, said spring element causing said ball to be biased against said shoulder during the pivoting action of said toggle element, said spring element being yieldably operative upon said switch element.

3. An electric switch comprising an open top case, a cover element for said case, an aperture in said cover element, a bearing seat within said aperture, a toggle element operable pivotably through said cover element, the external head of said toggle element being larger than the shaft thereof and larger than said aperture through which said shaft extends freely, and a ball collar staked upon said shaft after the latter has been projected through said aperture, said collar cooperating with said seat to perform as a pivot bearing for said toggle element.

4. An electric switch according to claim 3 and further comprising a switch lever mounted pivotally within said case and a spring biased actuator mounted between the inner end of said shaft and said lever, the biasing action of said actuator urging said ball collar into sliding and pivoting cooperation with said bearing seat.

5. An electric switch according to claim 3 wherein the cross-section dimension of said shaft is slightly greater than the cross-section of the aperture in said ball collar, the staking of said collar upon said aperture producing a strong press fit that firmly secures said collar to said shaft.

6. An electric switch according to claim 3 wherein the surface contour of said ball is matched by the contour of said bearing seat to provide a smooth pivot bearing between said elements. 

1. An electric switch comprising a case, a bushing mounted on said case, an annular curved shoulder in the interior of said bushing, a toggle element extending through said bushing and the aperture formed by said shoulder and into the interior of said case for pivotally actuating the switch, said toggle element being made of a stiff material, a portion of said toggle element extending externally of said bushing and being larger than said aperture, a stem portion on said toggle element of smaller cross-section than said aperture and extending therethrough, a pivot ball, an aperture in said pivot ball, said ball aperture being slightly smaller in diameter than the diameter of said stem, said pivot ball being staked upon said stem to a position where its surface pivotally bears against the matching curved surface of said shoulder.
 2. A switch according to claim 1 and further comprising at least one pivoting switching element in the interior of said case, an actuator mounted on the inner end of said stem and operative upon said switching element, a spring element on said actuator, said spring element causing said ball to be biased against said shoulder during the pivoting action of said toggle element, said spring element being yieldably operative upon said switch element.
 3. An electric switch comprising an open top case, a cover element for said case, an aperture in said cover element, a bearing seat within said aperture, a toggle element operable pivotaBly through said cover element, the external head of said toggle element being larger than the shaft thereof and larger than said aperture through which said shaft extends freely, and a ball collar staked upon said shaft after the latter has been projected through said aperture, said collar cooperating with said seat to perform as a pivot bearing for said toggle element.
 4. An electric switch according to claim 3 and further comprising a switch lever mounted pivotally within said case and a spring biased actuator mounted between the inner end of said shaft and said lever, the biasing action of said actuator urging said ball collar into sliding and pivoting cooperation with said bearing seat.
 5. An electric switch according to claim 3 wherein the cross-section dimension of said shaft is slightly greater than the cross-section of the aperture in said ball collar, the staking of said collar upon said aperture producing a strong press fit that firmly secures said collar to said shaft.
 6. An electric switch according to claim 3 wherein the surface contour of said ball is matched by the contour of said bearing seat to provide a smooth pivot bearing between said elements. 